Wiring process for avoiding wire breakage in rotor operation process

Abstract

The invention discloses a wiring process for avoiding wire breakage in a rotor operation process. The wiring process is characterized by comprising the following steps of: firstly, completing winding of an enameled wire in a rotor iron core groove; leading an enameled wire end needing to be connected with the commutator to the direction of the commutator; before the wire end of the enameled wire is hooked to a commutator wiring hook, the enameled wire is wound on a motor rotating shaft for at least half a circle; and the wire end of the enameled wire which is axially wound by at least half circle is hung on the corresponding commutator wiring hook, and the enameled wire is riveted, welded and fixed. The enameled wire is wound on the shaft by at least half circle, so that the originally suspended enameled wire is tightly attached to the surface of the rotating shaft, in the rotating process of the rotor, centrifugal force is not independently borne by a single enameled wire, but is converted into pressure and friction force on the rotating shaft, and the rotating shaft serves as a firm metal body and is sufficient to bear the force; therefore, the risk that the enameled wire is snapped due to centrifugal force is thoroughly avoided.

Description

Technical Field

[0001] This invention relates to rotor wiring technology, specifically a wiring technology to prevent wire breakage during rotor operation. Background Technology

[0002] In the manufacture of DC motors, the rotor winding (also known as the armature winding) is usually made of enameled copper wire, and the ends of the winding need to be electrically connected to the commutator segments. Currently, the most common process in the industry is to directly hook (or attach) the ends of the enameled wire to the terminals of the commutator riser segments, and then fix them by riveting and welding (such as TIG welding).

[0003] However, this traditional process has a significant drawback: the section of enameled wire between the connection point and the winding body (hereinafter referred to as the "suspended section") is suspended without any support. When the rotor rotates at high speed, this suspended section will be subjected to enormous centrifugal force. This centrifugal force is entirely borne by the strength of the enameled wire material itself and the firmness of the weld joint. Under long-term operation, this can easily lead to: Fatigue fracture: Under the alternating stress of centrifugal force, the enameled wire undergoes metal fatigue and eventually fractures near the solder joint where the stress is most concentrated or in the middle of the suspended section. Wire breakage and short circuit: A broken enameled wire, thrown out by centrifugal force, may come into contact with adjacent commutator segments or the rotor core, causing a short circuit and leading to motor failure; this seriously affects the motor's service life and reliability. Therefore, a wiring process is proposed to avoid wire breakage during rotor operation. Summary of the Invention

[0004] The purpose of this invention is to solve the above problems by proposing a wiring process that avoids wire breakage during rotor operation.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a wiring process to avoid wire breakage during rotor operation, characterized by the following wiring process: a. Winding: First, complete the winding of the enameled wire in the rotor core slots; b. Pre-lead the wire ends: Lead the enameled wire ends that need to be connected to the commutator to the direction of the commutator; c. Axial winding: Before hooking the enameled wire end to the commutator hook, first wind the enameled wire around the motor shaft at least half a turn; d. Hook and fix: Hook the end of the enameled wire that has been axially wound at least half a turn onto the corresponding commutator hook and fix the enameled wire by riveting and welding.

[0006] Further preferably, when winding the enameled wire onto the motor shaft, ensure that the enameled wire is fully in contact with the shaft surface.

[0007] In a further preferred embodiment, when the enameled wire end is riveted after being hooked onto the commutator hook, the width of the enameled wire at the riveted point is not less than two-thirds of the original diameter of the enameled wire.

[0008] The beneficial effects of the present invention are as follows: by winding the enameled wire around the shaft at least half a turn, the originally suspended enameled wire is tightly attached to the surface of the shaft. During the rotation of the rotor, the centrifugal force is no longer borne by a single enameled wire, but is converted into pressure and friction on the shaft. As a sturdy metal body, the shaft is sufficient to withstand this force, thereby completely avoiding the risk of the enameled wire breaking due to centrifugal force. At the same time, the structure of winding at least half a turn provides a flexible stress release path. The vibration and slight deformation during motor operation can be absorbed by the slight sliding or deformation of this section of the enameled wire wound on the shaft, avoiding the stress being completely concentrated at the weld point, which is a weak part, and significantly improving fatigue resistance. This process requires no additional parts; it only adds a simple winding action to the existing process flow. It increases production costs and equipment investment by almost nothing, yet brings a qualitative improvement in reliability. Detailed Implementation

[0009] Below, we will further explain the wiring process for avoiding wire breakage during rotor operation as described in this invention.

[0010] It should be noted that all directional indications in the embodiments of the present invention, such as up, down, left, right, front, back, etc., are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0011] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixing," etc., should be interpreted broadly; for example, "fixing" can mean a fixed connection, a detachable connection, or an integral part; it can also mean a mechanical connection, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0012] A wiring process to prevent wire breakage during rotor operation, characterized by the following wiring process: The winding process begins with winding the enameled wire inside the rotor core slots. Pre-lead the wire ends, leading the enameled wire ends that need to be connected to the commutator towards the commutator direction; Axial winding involves first winding the enameled wire at least 180° around the motor shaft to form an axial winding section before attaching the end of the enameled wire to the commutator hook. When winding the enameled wire onto the motor shaft, ensure that the wire is fully in contact with the shaft surface and maintains a certain tension. By winding the wire at least half a turn, a flexible stress release path is provided. Vibrations and minor deformations during motor operation can be absorbed by the slight sliding or deformation of this section of the wire wound on the shaft, preventing stress from being concentrated entirely at the weld point, a vulnerable area, and significantly improving fatigue resistance. In actual use, the number of turns of the enameled wire can be adaptively adjusted according to the motor's maximum operating speed and the magnitude of the centrifugal force. For secure connection, attach the end of the enameled wire, which has been axially wound at least half a turn, to the corresponding commutator hook and then rivet and weld the enameled wire to secure it. When riveting the enameled wire end after it is hooked onto the commutator hook, the width of the enameled wire at the riveted point should not be less than two-thirds of the original diameter of the enameled wire. This is to avoid excessive riveting, which would result in the riveted point being too narrow and thus easily break, seriously affecting the service life and reliability of the motor. By winding the enameled wire at least half a turn around the shaft, the originally suspended enameled wire is tightly attached to the surface of the shaft. During the rotation of the rotor, the centrifugal force is no longer borne by a single enameled wire, but is converted into pressure and friction on the shaft. As a sturdy metal body, the shaft is able to withstand this force, thus completely avoiding the risk of the enameled wire breaking due to centrifugal force. This process requires no additional parts; it only adds a simple winding action to the existing process flow. It increases production costs and equipment investment by almost nothing, yet brings a qualitative improvement in reliability.

[0013] The scope of protection of this invention is not limited to the above embodiments and their variations. Conventional modifications and substitutions made by those skilled in the art based on the content of these embodiments are all within the scope of protection of this invention.

Claims

1. A wiring process to avoid wire breakage during rotor operation, characterized in that: The wiring process is as follows: a. Winding: First, complete the winding of the enameled wire in the rotor core slots; b. Pre-lead the wire ends: Lead the enameled wire ends that need to be connected to the commutator to the direction of the commutator; c. Axial winding: Before hooking the enameled wire end to the commutator hook, first wind the enameled wire around the motor shaft at least half a turn. The vibration and slight deformation during motor operation can be absorbed by the slight sliding or deformation of this section of the enameled wire wound on the shaft, avoiding the stress being completely concentrated at the weld point, which is a weak part. d. Hook and fix: Hook the end of the enameled wire that has been axially wound at least half a turn onto the corresponding commutator hook and fix the enameled wire by riveting and welding.

2. The wiring process for avoiding wire breakage during rotor operation according to claim 1, characterized in that: When winding the enameled wire onto the motor shaft, ensure that the enameled wire is fully in contact with the shaft surface.

3. The wiring process for avoiding wire breakage during rotor operation according to claim 1, characterized in that: When the enameled wire end is riveted after being hooked onto the commutator terminal hook, the width of the enameled wire at the riveted point shall not be less than two-thirds of the original diameter of the enameled wire.